Electrosurgical Pencil Including Improved Controls

ABSTRACT

The present disclosure relates to electrosurgical devices having a plurality of hand-accessible variable controls. An electrosurgical device configured for connection to a source of electrosurgical energy is provided and includes a housing; an electrical circuit supported within the housing, the electrical circuit being connectable to the source of electrosurgical energy; and a controller slidably supported on the housing, wherein the controller is configured to exert a force on the electrical circuit to affect a change in the electrical circuit and to exert a force on a surface of the housing to provide a tactile feedback to a user of the electrosurgical device as the controller is moved relative to the housing.

CROSS-REFERENCE TO RELATED APPLICATION

The present application claims the benefit of and priority to U.S.Provisional Application Ser. No. 61/040,836, filed on Mar. 31, 2008, theentire content of which is incorporated herein by reference.

BACKGROUND

1. Technical Field

The present disclosure relates generally to electrosurgical instrumentsand, more particularly, to an electrosurgical pencil having a pluralityof hand-accessible variable controls.

2. Background of Related Art

Electrosurgical instruments have become widely used by surgeons inrecent years. Accordingly, a need has developed for equipment andinstruments which are easy to handle, are reliable and are safe in anoperating environment. By and large, most electrosurgical instrumentsare hand-held instruments, e.g., an electrosurgical pencil, whichtransfer radio-frequency (RF) electrical or electrosurgical energy to atissue site. The electrosurgical energy is returned to theelectrosurgical source via a return electrode pad positioned under apatient (i.e., a monopolar system configuration) or a smaller returnelectrode positionable in bodily contact with or immediately adjacent tothe surgical site (i.e., a bipolar system configuration). The waveformsproduced by the RF source yield a predetermined electrosurgical effectknown generally as electrosurgical cutting and fulguration.

As used herein the term “electrosurgical pencil” is intended to includeinstruments which have a handpiece which is attached to an activeelectrode and which is used to cauterize, coagulate and/or cut tissue.Typically, the electrosurgical pencil may be operated by a handswitch ora foot switch. The active electrode is an electrically conductingelement which is usually elongated and may be in the form of a thin flatblade with a pointed or rounded distal end. Alternatively, the activeelectrode may include an elongated narrow cylindrical needle which issolid or hollow with a flat, rounded, pointed or slanted distal end.Typically electrodes of this sort are known in the art as “blade”,“loop” or “snare”, “needle” or “ball” electrodes.

As mentioned above, the handpiece of the electrosurgical pencil isconnected to a suitable electrosurgical energy source (i.e., generator)which produces the radio-frequency electrical energy necessary for theoperation of the electrosurgical pencil. In general, when an operationis performed on a patient with an electrosurgical pencil, electricalenergy from the electrosurgical generator is conducted through theactive electrode to the tissue at the site of the operation and thenthrough the patient to a return electrode. The return electrode istypically placed at a convenient place on the patient's body and isattached to the generator by a conductive material. Typically, thesurgeon activates the controls on the electrosurgical pencil to selectthe modes/waveforms to achieve a desired surgical effect.

The power or energy parameters are typically controlled from outside thesterile field which requires an intermediary like a circulating nurse tomake such adjustment.

A typical electrosurgical generator has numerous controls for selectingan electrosurgical output. For example, the surgeon can select varioussurgical “modes” to treat tissue: cut, blend (blend levels 1-3), lowcut, desiccate, fulgurate, spray, etc. The surgeon also has the optionof selecting a range of power settings typically ranging from 1-300 W.As can be appreciated, this gives the surgeon a great deal of varietywhen treating tissue. However, so many options also tend to complicatesimple surgical procedures and may lead to confusion. Moreover, surgeonstypically follow preset control parameters and stay within known modesand power settings. Therefore, there exists a need to allow the surgeonto selectively control and easily select and regulate the various modesand power settings utilizing simple and ergonomically friendly controlsassociated with the electrosurgical pencil.

Existing electrosurgical instrument systems allow the surgeon to changebetween two pre-configured settings (i.e., coagulation and cutting) viatwo discrete switches disposed on the electrosurgical pencil itself.Other electrosurgical instrument systems allow the surgeon to incrementthe power applied when the coagulating or cutting switch of theinstrument is depressed by adjusting or closing a switch on theelectrosurgical generator. The surgeon then needs to visually verify thechange in the power being applied by looking at various displays and/ormeters on the electrosurgical generator. In other words, all of theadjustments to the electrosurgical instrument and parameters beingmonitored during the use of the electrosurgical instrument are typicallylocated on the electrosurgical generator. As such, the surgeon mustcontinually monitor the electrosurgical generator during the surgicalprocedure. Furthermore, someone outside the sterile field mustcontinually adjust the parameters of the electrical instrument, whichprolongs the duration of the procedure.

Accordingly, the need exists for electrosurgical instruments which donot require the surgeon to continually monitor the electrosurgicalgenerator during the surgical procedure. Further, a need exists forelectrosurgical instruments, which permit the surgeon to accuratelyself-adjust the electrical parameters of the instrument from within thesterile field. In addition, the need exists for electrosurgicalinstruments which may be configured such that the power output can beadjusted without the surgeon having to turn his/her vision away from theoperating site and toward the electrosurgical generator.

SUMMARY

The present disclosure relates to electrosurgical pencils having aplurality of hand-accessible variable controls.

According to an aspect of the present disclosure, an electrosurgicalpencil is provided including an elongated housing configured to supportan electrocautery electrode extending distally therefrom; at least onevoltage divider network supported on the housing, the at least onevoltage divider network operable to electrically connect to a source ofelectrosurgical energy for controlling at least one of an intensity anda mode of electrosurgical energy being delivered to the electrocauteryelectrode; and an intensity controller slidably supported on thehousing. The intensity controller is configured to exert a force on theat least one voltage divider network and to provide a tactile feedbackto a user of the electrosurgical pencil as the intensity controller ismoved relative to the housing.

The intensity controller may include a nub extending from a surfacethereof. The nub may be configured to contact the at least one voltagedivider network and affect the at least one voltage divider network asthe intensity controller is moved relative to the housing.

The intensity controller may include a spring plunger assemblyconfigured to operatively engage a tactile feature formed in thehousing. The spring plunger assembly may include a stem and a biasingmember. The stem may be disposed on a side opposite to the nub and isconfigured to retain an actuator.

The biasing member may be configured to maintain the actuator in contactwith the tactile feature formed in the housing. The actuator may bedisposed at one of a distal, a proximal and a substantially alignedlocation with respect to the nub.

The intensity controller may include a spring lever assembly configuredto operatively engage a tactile feature formed in the housing. Thespring lever assembly may include a lever and a biasing member formaintaining the lever in contact with the tactile feature. The lever maybe pivotally connected to a body portion of the intensity controller, ona side opposite to the nub.

The biasing member may be a spring.

A tip of the lever may be disposed at one of a distal, a proximal and asubstantially aligned location with respect to the nub.

According to another aspect of the present disclosure, anelectrosurgical device configured for connection to a source ofelectrosurgical energy is provided. The electrosurgical device includesa housing; an electrical circuit supported within the housing, theelectrical circuit being connectable to the source of electrosurgicalenergy; and a controller slidably supported on the housing, wherein thecontroller is configured to exert a force on the electrical circuit toaffect a change in the electrical circuit and to provide a tactilefeedback to a user of the electrosurgical device as the controller ismoved relative to the housing.

The controller may include a nub extending from a surface thereof andbeing dimensioned to contact the electrical circuit. The electricalcircuit may be a voltage divider network capable of controlling at leastone of an intensity and a mode of electrosurgical energy beingdelivered, and wherein the nub is configured to contact the voltagedivider network and affect a change in at least one of the intensity andthe mode of electrosurgical energy being delivered as the controller ismoved relative to the housing.

The controller may include a spring plunger assembly configured tooperatively engage a tactile feature formed in the housing. The springplunger assembly may include a stem and a biasing member. The stem maybe disposed on a side opposite to the nub and is configured to retain anactuator. The biasing member may be configured to maintain the actuatorin contact with the tactile feature formed in the housing. The actuatormay be disposed at one of a distal, a proximal and a substantiallyaligned location with respect to the nub.

The controller may include a spring lever assembly configured tooperatively engage a tactile feature formed in the housing. The springlever assembly may include a lever and a biasing member for maintainingthe lever in contact with the tactile feature. The lever may bepivotally connected to a body portion of the intensity controller, on aside opposite to the nub. The biasing member may be a spring.

A tip of the lever may be disposed at one of a distal, a proximal and asubstantially aligned location with respect to the nub.

According to a further aspect of the present disclosure, anelectrosurgical pencil is provided including an elongated housingconfigured to support an electrocautery electrode extending distallytherefrom; at least one voltage divider network supported on thehousing, the at least one voltage divider network operable toelectrically connect to the source of electrosurgical energy forcontrolling at least one of an intensity and a mode of electrosurgicalenergy being delivered to the electrocautery electrode; and an intensitycontroller slidably supported on the housing, wherein the intensitycontroller is configured to exert a force on the at least one voltagedivider network and provide a tactile feedback to a user of theelectrosurgical pencil as the intensity controller is moved relative tothe housing.

The intensity controller may include a lever pivotally connected to abody portion thereof and contactable with the housing and the at leastone voltage divider network. The lever may include a first endconfigured for engagement with a tactile feature formed in the housing.The lever may include a second end configured for engagement with the atleast one voltage divider network.

The intensity controller may include a biasing member configured tomaintain a first end of the lever in contact with the tactile featureformed in the housing. The intensity controller may include a biasingmember configured to maintain a second end of the lever in contact withthe at least one voltage divider network. The intensity controller mayinclude a biasing member configured to maintain a first end of the leverin contact with the tactile feature formed in the housing and tomaintain a second end of the lever in contact with the at least onevoltage divider network.

The biasing members may be one of a coil spring, a tension spring and acompression spring. The tactile feature may include one or more adjacentdetents. In use, movement of the first end of the lever into the one ormore adjacent detents may cause the second end of the lever tosubstantially strike the at least one voltage divider network.

According to yet another aspect of the present disclosure, anelectrosurgical device configured for connection to a source ofelectrosurgical energy is provided. The electrosurgical device includesa housing; an electrical circuit supported within the housing, theelectrical circuit being connectable to the source of electrosurgicalenergy; and a controller slidably supported on the housing, wherein thecontroller is configured to exert a force on the electrical circuit toaffect a change in the electrical circuit and to exert a force on asurface of the housing to provide a tactile feedback to a user of theelectrosurgical device as the controller is moved relative to thehousing.

The electrical circuit may comprise at least one voltage divider networkcapable of controlling at least one of an intensity and a mode ofelectrosurgical energy being delivered, and wherein the controller mayinclude a lever pivotally connected to a body portion thereof andcontactable with the housing and the at least one voltage dividernetwork.

The lever may include a first end configured for engagement with atactile feature formed in the housing. The lever may include a secondend configured for engagement with the at least one voltage dividernetwork.

The controller may include a biasing member configured to maintain afirst end of the lever in contact with the tactile feature formed in thehousing. The controller may include a biasing member configured tomaintain a second end of the lever in contact with the at least onevoltage divider network. The controller may include a biasing memberconfigured to maintain a first end of the lever in contact with thetactile feature formed in the housing and to maintain a second end ofthe lever in contact with the at least one voltage divider network. Thebiasing members may be one of a coil spring, a tension spring and acompression spring.

The tactile feature may include one or more adjacent detents.

In use, movement of the first end of the lever into the one or moreadjacent detents may cause the second end of the lever to substantiallystrike the at least one voltage divider network.

According to still another aspect of the present disclosure, anelectrosurgical pencil is provided including an elongated housingconfigured to support an electrocautery electrode extending distallytherefrom; at least one voltage divider network supported on thehousing, the at least one voltage divider network operable toelectrically connect to the source of electrosurgical energy forcontrolling at least one of an intensity and a mode of electrosurgicalenergy being delivered to the electrocautery electrode, wherein the atleast one voltage divider network defines a plurality of tactileenhancement features; and an intensity controller slidably supported onthe housing, wherein the intensity controller is configured to exert aforce on the at least one voltage divider network and engage the tactileenhancement feature and provide a tactile feedback to a user of theelectrosurgical pencil as the intensity controller is moved relative tothe housing.

The electrosurgical pencil may further include a tactile mask overlyingat least a portion of the at least one voltage divider network, whereinthe tactile mask defines the plurality of tactile enhancement regions.The tactile enhancement features of the tactile mask may include atleast one aperture formed therein.

The intensity controller may include a tactile feedback transmittingfeature configured to project through the at least one aperture formedin the tactile mask to selectively engage the at least one voltagedivider network. The tactile feedback transmitting feature may includeat least one of an actuator and a nub selectively positionable withinthe aperture of the tactile mask.

At least one of an actuator and a nub may extend from a surface of theintensity controller, in a direction toward the tactile mask.

The tactile feedback transmitting feature may further comprise a springplunger assembly including a biasing member for maintaining the tactilefeedback transmitting feature in contact with at least one of thevoltage divider network and the tactile mask.

The tactile feedback transmitting feature may be configured toselectively strike the at least one voltage divider network.

According to yet another aspect of the present disclosure, anelectrosurgical device, configured for connection to a source ofelectrosurgical energy, is provided. The electrosurgical devicecomprises a housing; an electrical circuit supported within the housing,the electrical circuit being connectable to the source ofelectrosurgical energy, wherein the electrical circuit is provided withat least one tactile enhancement feature; and a controller slidablysupported on the housing, wherein the controller is configured to exerta force on the electrical circuit to affect a change in the electricalcircuit and to exert a force on a surface of the housing to engage thetactile enhancement feature and provide a tactile feedback to a user ofthe electrosurgical device as the controller is moved relative to thehousing.

The electrosurgical device may further include a tactile mask overlyingat least a portion of electrical circuit, wherein the tactile maskdefines the plurality of tactile enhancement regions.

The tactile enhancement features of the tactile mask may include atleast one aperture formed therein.

The controller may include a tactile feedback transmitting featureconfigured to project through the at least one aperture formed in thetactile mask to selectively engage the electrical circuit. The tactilefeedback transmitting feature may include at least one of an actuatorand a nub selectively positionable within the aperture of the tactilemask. At least one of an actuator and a nub may extend from a surface ofthe controller, in a direction toward the tactile mask.

The tactile feedback transmitting feature may further include a springplunger assembly including a biasing member for maintaining the tactilefeedback transmitting feature in contact with at least one of theelectrical circuit and the tactile mask.

The tactile feedback transmitting feature may be configured toselectively strike the electrical circuit.

The electrical circuit may include at least one voltage divider network.

According to still another aspect of the present disclosure, anelectrosurgical pencil is provided including an elongated housingconfigured to support an electrocautery electrode extending distallytherefrom; at least one voltage divider network supported on thehousing, the at least one voltage divider network operable toelectrically connect to the source of electrosurgical energy forcontrolling at least one of an intensity and a mode of electrosurgicalenergy being delivered to the electrocautery electrode; and an intensitycontroller slidably supported on the housing, wherein the intensitycontroller is configured to exert a force on each of the housing and theat least one voltage divider network, wherein the intensity controllerprovides a tactile feedback to a user of the electrosurgical pencil asthe intensity controller is moved relative to the housing.

The intensity controller may include a torsion spring pivotallysupported on a body portion thereof, wherein the torsion spring is incontact with at least one of the housing and the electrical circuit. Thetorsion spring may include a first leg configured for engagement with atactile feature formed in the housing. The torsion spring may include asecond leg configured for engagement with the at least one voltagedivider network.

The torsion spring may include a first leg configured for engagementwith a tactile feature formed in the housing and a second leg configuredfor engagement with the at least one voltage divider network.

The intensity controller may include a link assembly pivotally supportedon a body portion. The link assembly may include a first leg configuredfor engagement with a tactile feature formed in the housing; and asecond leg configured for engagement with the at least one voltagedivider network.

The link assembly may further include a biasing member interposedbetween the first leg and the second leg for maintaining the first legin engagement with the tactile feature formed in the housing and formaintaining the second leg in engagement with the at least one voltagedivider network.

The biasing member may be configured for maintaining the first leg inengagement with the tactile feature formed in the housing. The biasingmember may be configured for maintaining the second leg in engagementwith the at least one voltage divider network.

According to still another aspect of the present disclosure, anelectrosurgical device, configured for connection to a source ofelectrosurgical energy, is provided. The electrosurgical devicecomprises a housing; an electrical circuit supported within the housing,the electrical circuit being connectable to the source ofelectrosurgical energy; and a controller slidably supported on thehousing, wherein the controller is configured to exert a force on eachof the housing and the electrical circuit to affect a change in theelectrical circuit and to provide a tactile feedback to a user of theelectrosurgical device as the controller is moved relative to thehousing.

The controller may include a torsion spring pivotally supported on abody portion thereof, wherein the torsion spring is in contact with atleast one of the housing and the electrical circuit. The torsion springmay include a first leg configured for engagement with a tactile featureformed in the housing. The torsion spring may include a second legconfigured for engagement with the electrical circuit. The torsionspring may include a first leg configured for engagement with a tactilefeature formed in the housing and a second leg configured for engagementwith the electrical circuit.

The controller may include a link assembly pivotally supported on a bodyportion. The link assembly may include a first leg configured forengagement with a tactile feature formed in the housing; and a secondleg configured for engagement with the electrical circuit. The linkassembly may further include a biasing member interposed between thefirst leg and the second leg for maintaining the first leg in engagementwith the tactile feature formed in the housing and for maintaining thesecond leg in engagement with the electrical circuit. The biasing membermay be configured for maintaining the first leg in engagement with thetactile feature formed in the housing. The biasing member may beconfigured for maintaining the second leg in engagement with theelectrical circuit.

The electrical circuit may include at least one voltage divider networksupported on the housing, the at least one voltage divider networkoperable to electrically connect to the source of electrosurgical energyfor controlling at least one of an intensity and a mode ofelectrosurgical energy being delivered to the electrocautery electrode.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate embodiments of the invention, andtogether with a general description of the invention given above, andthe detailed description of the embodiments given below, serve toexplain the principles of the invention.

FIG. 1 is a perspective view of a prior art electrosurgical systemincluding an electrosurgical generator and an electrosurgical pencil;

FIG. 2 is an exploded perspective view of the electrosurgical pencil ofFIG. 1;

FIG. 3 is a longitudinal, cross-sectional, side elevational view of theelectrosurgical pencil of FIGS. 1 and 2;

FIG. 4 is an enlarged view of the indicated area of detail of FIG. 3;

FIG. 5 is an exploded perspective view of a voltage divider network;

FIG. 6A is a schematic side elevational view of a slider according to anembodiment of the present disclosure, for use in an electrosurgicalpencil as shown in FIGS. 1-4;

FIG. 6B is a schematic side elevational view of a slider according toanother embodiment of the present disclosure, for use in anelectrosurgical pencil as shown in FIGS. 1-4;

FIG. 6C is a schematic side elevational view of a slider according toyet another embodiment of the present disclosure, for use in anelectrosurgical pencil as shown in FIGS. 1-4;

FIG. 6D is a schematic perspective view, with parts separated, of aslider according to a further embodiment of the present disclosure, foruse in an electrosurgical pencil as shown in FIGS. 1-4;

FIG. 7A is a schematic side elevational view of an alternate slideraccording to an embodiment of the present disclosure, for use in anelectrosurgical pencil as shown in FIGS. 1-4;

FIG. 7B is a schematic side elevational view of the alternate slideraccording to another embodiment of the present disclosure, for use in anelectrosurgical pencil as shown in FIGS. 1-4;

FIG. 7C is a schematic side elevational view of the alternate slideraccording to yet another embodiment of the present disclosure, for usein an electrosurgical pencil as shown in FIGS. 1-4;

FIG. 8A is a schematic illustration of a further alternate slider and atactile mask according to an embodiment of the present disclosure, foruse in an electrosurgical pencil as shown in FIGS. 1-4;

FIG. 8B is a schematic illustration of the further alternate slideraccording and a tactile mask to another embodiment of the presentdisclosure, for use in an electrosurgical pencil as shown in FIGS. 1-4;

FIG. 9A is a schematic side elevational view of an alternate slideraccording to an embodiment of the present disclosure, for use in anelectrosurgical pencil as shown in FIGS. 1-4; and

FIG. 9B is a schematic side elevational view of a further alternateslider according to another embodiment of the present disclosure, foruse in an electrosurgical pencil as shown in FIGS. 1-4.

DETAILED DESCRIPTION

Preferred embodiments of the presently disclosed electrosurgical pencilwill now be described in detail with reference to the drawing figureswherein like reference numerals identify similar or identical elements.As used herein, the term “distal” refers to that portion which isfurther from the user while the term “proximal” refers to that portionwhich is closer to the user or surgeon.

FIG. 1 sets forth a perspective view of an electrosurgical systemincluding an electrosurgical pencil 100 constructed in accordance with aprior art embodiment. While the following description will be directedtowards electrosurgical pencils it is envisioned that the features andconcepts (or portions thereof) of the present disclosure can be appliedto any electrosurgical type instrument, e.g., forceps, suctioncoagulators, vessel sealers, wands, etc.

As seen in FIGS. 1-5, electrosurgical pencil 100 includes an elongatedhousing 102 having a right-half shell section 102 a and a left-halfshell section 102 b. As seen in FIGS. 1 and 2, when right and left-halfshell sections 102 a, 102 b are connected to one another, a distalopening 103 a is defined therebetween, through which an electrode 106extends, and a proximal opening 103 b (see FIG. 2) is definedtherebetween, through which connecting cable 224 (see FIG. 1) extends.As seen in FIG. 1, electrosurgical pencil 100 is coupled to anelectrosurgical generator “G” via a plug assembly 200 connected toconnecting cable 224.

As seen in FIG. 2, electrosurgical pencil 100 further includes anelectrode receptacle 104 disposed at a distal end of housing 102, and areplaceable electrode 106 operatively and removably connectable toelectrode receptacle 104.

With continued reference to FIGS. 1-3, electrosurgical pencil 100includes three activation buttons 120 a-120 c, each of which isreciprocally supported in a carrier 121 (see FIG. 2) of a controllerunit which is supported in housing 102. Each activation button 120 a-120c includes a portion which extends through an upper surface of housing102.

As seen in FIGS. 2 and 3, each activation button 120 a-120 c isoperatively supported on a respective tactile element 122 a-122 c formedin a switch plate 124.

Each activation button 120 a-120 c controls the transmission of RFelectrical energy supplied from generator “G” to electrode 106. Switchplate 124 is positioned over the top of a voltage divider network 127(hereinafter “VDN 127”) such that tactile elements 122 a-122 c are inoperative association therewith.

As seen in FIGS. 1-4, electrosurgical pencil 100 includes an intensitycontroller 128 slidingly supported in housing 102. Intensity controller128 includes a pair of nubs 129 a, 129 b which are slidingly supported,one each, in respective guide channels 130 a, 130 b (see FIG. 1).

As seen in FIGS. 3 and 4, intensity controller 128 includes a third nub129 c extending from a bottom surface thereof which contacts and pressesinto or against VDN 127. As seen in FIG. 5, VDN 127 includes electricalcontacts 144 a provided on upper layer 140 a and resistive element 144 bon lower layer 140 b. In this manner, as intensity controller 128 isdisplaced in a distal and proximal direction relative to housing 102,third nub 129 c moves along VDN 127, thereby pressing electrical contact144 a from upper layer 140 a of VDN 127 against resistance element 144 bof lower layer 140 b of VDN 127. In so doing, a resistance value ofresistance element 144 b is changed thereby changing the value of thevoltage measured by electrosurgical generator “G”. The electrosurgicalgenerator “G” in turn varies the intensity of the waveform beingtransmitted to electrode 106.

Slidable manipulation or movement of intensity controller 128 adjuststhe power parameters (e.g., voltage, power and/or current intensity)and/or the power verses impedance curve shape to affect the outputintensity of the waveform.

In order to vary the intensity of the power parameters ofelectrosurgical pencil 100, the surgeon displaces intensity controller128, by manipulating at least one of nubs 129 a, 129 b, in either of thedirections indicated by double-headed arrow “X” (see FIG. 3).

Intensity controller 128 is also operable to provide a degree of tactilefeedback by the inter-engagement of resilient finger 128 a of intensitycontroller 128 in detents 131 formed along an inner surface ofright-half shell section 102 a (see FIGS. 3 and 4).

As seen in FIG. 5, VDN 127 includes a pair of layers 140 a, 140 b ofresilient material each supporting a plurality of electrical contacts142 a, 142 b thereon. Electrical contacts 142 a from an upper layer 140a of VDN 127 are in juxtaposed electrical relation with respect toelectrical contacts 142 b from a lower layer 140 b of VDN 127. Theelectrical contacts 142 a, 142 b of the upper and the lower layers 140a, 140 b of VDN 127 are in juxtaposed relation with respective tactileelements 122 a-122 c.

Upper and lower layers 140 a, 140 b of VDN 127 are separated by adividing layer 140 c. Dividing layer 140 c includes a first series ofapertures 142 c formed therein which are in vertical registration withelectrical contacts 142 a, 142 b. Dividing layer 140 c includes a secondaperture 144 c formed therein which is in vertical registration betweenelectrical contacts 144 a provided on upper layer 140 a and a variableresistance element 144 d provided on lower layer 140 b. Upper layer 140a, lower layer 140 b, and dividing layer 140 c are supported on asupport layer 140 d.

In operation, and depending on the particular electrosurgical functiondesired, the surgeon depresses one of activation buttons 120 a-120 c, inthe direction indicated by arrow “Y” (see FIG. 3) thereby urging and/ordeflecting a corresponding tactile element 122 a-122 c against VDN 127and thereby causing the respective electrical contact 142 a of upperlayer 140 a to electrically engage the respective electrical contact 142b of the lower layer 140 b. In so doing, a respective characteristicvoltage is generated and measured by electrosurgical generator “G”. Inturn, depending on the characteristic voltage generated, generator “C”selects and transmits an appropriate waveform output to electrocauteryblade 106.

Reference may be made to U.S. application Ser. No. 11/337,990 filed onJan. 24, 2006, the entire content of which is incorporated herein byreference, for a more detailed discussion of the construction andoperation of electrosurgical pencil 100.

Turning now to FIGS. 6A-6D, a series of sliders or intensity controllers228 according to an embodiment of the present disclosure is shown.Sliders 228 are configured to increase a contact force exerted on VDN127 while maintaining a degree of facility for an end user to moveslider 228 relative to housing 102 of electrosurgical pencil 100.

As seen in FIG. 6A, a slider 228 a may include a body portion 228 a ₁and at least one arm 228 a ₂ extending from body portion 228 a ₁ andconfigured for slidable engagement in guide channels 130 a, 130 b (seeFIG. 1) of electrosurgical pencil 100. Slider 228 a includes a nub 228 a₃ extending or projecting from a bottom surface thereof, such as, forexample, from a bottom surface of body portion 228 a ₁. Slider 228 afurther includes a spring plunger assembly having a stem 228 a ₄extending from body portion 228 a ₁, on a side opposite nub 228 a ₃, anddefining a recess configured to retain a biasing member 228 a ₅ and anactuator 228 a ₆ therein. The spring plunger assembly is located distalor proximal of nub 228 a ₃.

In use, as slider 228 a is moved distally and proximally relative tohousing 102 of electrosurgical pencil 100, nub 228 a ₃ moves along VDN127 thereby affecting VDN 127 while actuator 228 a ₆ of the springplunger assembly inter-engages with detents or tactile features 131formed in housing 102 of electrosurgical pencil 100 to thereby provide adegree of tactile feedback to the user of electrosurgical pencil 100.Biasing member 228 a ₅ functions to maintain nub 228 a ₃ in contact withVDN 127 and actuator 228 a ₆ of the spring plunger assembly in contactwith detents or tactile features 131 formed in housing 102 ofelectrosurgical pencil 100.

As seen in FIG. 6B, a slider 228 b may include a body portion 228 b ₁and at least one arm 228 b ₂ extending from body portion 228 b ₁ andconfigured for slidable engagement in guide channels 130 a, 130 b (seeFIG. 1) of electrosurgical pencil 100. Slider 228 b includes a nub 228 b₃ extending or projecting from a bottom surface thereof, such as, forexample, from a bottom surface of body portion 228 b ₁. Slider 228 bfurther includes a spring lever assembly having a stem 228 b ₄ extendingfrom body portion 228 b ₁, on a side opposite nub 228 b ₃, and defininga recess configured to retain a biasing member 228 b ₅ therein. Thespring lever assembly further includes a lever 228 b ₆ pivotallyconnected to body portion 228 b ₁ and having a tip 228 b ₇ configured toextend over or overlie biasing member 228 b ₅. The spring lever assemblyis configured such that stem 228 b ₄ is located distal or proximal ofnub 228 b ₃ and such that lever 228 b ₆ extends away from nub 228 b ₃.

In use, as slider 228 b is moved distally and proximally relative tohousing 102 of electrosurgical pencil 100, nub 228 b ₃ moves along VDN127 thereby affecting VDN 127 while tip 228 b ₇ of lever 228 b ₆ of thespring lever assembly inter-engages with detents or tactile features 131formed in housing 102 of electrosurgical pencil 100 to thereby provide adegree of tactile feedback to the user of electrosurgical pencil 100.Biasing member 228 b ₅ functions to maintain nub 228 b ₃ in contact withVDN 127 and tip 228 b ₇ of lever 228 b ₆ of the spring lever assembly incontact with detents or tactile features 131 formed in housing 102 ofelectrosurgical pencil 100.

As seen in FIG. 6C, a slider 228 c may include a body portion 228 c ₁and at least one arm 228 c ₂ extending from body portion 228 c ₁ andconfigured for slidable engagement in guide channels 130 a, 130 b (seeFIG. 1) of electrosurgical pencil 100. Slider 228 c includes a nub 228 c₃ extending or projecting from a bottom surface thereof, such as, forexample, from a bottom surface of body portion 228 c ₁. Slider 228 cfurther includes a spring lever assembly having a biasing member 228 c ₅supported on body portion 228 c ₁, on a side opposite nub 228 c ₃, and alever 228 c ₆ pivotally connected to body portion 228 c ₁ and having atip 228 c ₇ configured to extend over or overlie biasing member 228 c ₅.The spring lever assembly is configured such that biasing member 228 c ₅is located distal or proximal of nub 228 c ₃ and such that lever 228 c ₆extends away from nub 228 c ₃.

In use, as slider 228 c is moved distally and proximally relative tohousing 102 of electrosurgical pencil 100, nub 228 c ₃ moves along VDN127 thereby affecting VDN 127 while tip 228 c ₇ of lever 228 c ₆ of thespring lever assembly inter-engages with detents or tactile features 131formed in housing 102 of electrosurgical pencil 100 to thereby provide adegree of tactile feedback to the user of electrosurgical pencil 100.Biasing member 228 c ₅ functions to maintain nub 228 c ₃ in contact withVDN 127 and tip 228 c ₇ of lever 228 c ₆ of the spring lever assembly incontact with detents or tactile features 131 formed in housing 102 ofelectrosurgical pencil 100.

In each of sliders 228 a-228 c shown in FIGS. 6A-6C and described above,it is contemplated that in some embodiments that actuator 228 a ₆, ortips 228 b ₇, 228 c ₇ of levers 228 b ₆, 228 c ₆ may axially overlierespective nubs 228 a ₃-228 c ₃. In this manner, the force of thebiasing member 228 a ₅-228 c ₅ acts directly in line with respectivenubs 228 a ₃-228 c ₃.

Although the embodiment in FIGS. 6B-6C is shown to a use coil spring asthe biasing member, it is contemplated that these slider designs mayalternatively incorporate torsion springs of the type shown in FIG. 6D.As seen in FIG. 6D, a slider 228 d may include a body portion 228 d ₁and at least one arm 228 d ₂ extending from body portion 228 d ₁ andconfigured for slidable engagement in guide channels 130 a, 130 b (seeFIG. 1) of electrosurgical pencil 100. Slider 228 d includes a nub 228 d₃ extending or projecting from a bottom surface thereof, such as, forexample, from a bottom surface of body portion 228 d ₁. Slider 228 dfurther includes a torsion spring lever assembly supported on bodyportion 228 d ₁ having a biasing member 228 d ₅ and a connector rod 228d ₈ pivotally connecting lever 228 d ₆ to body portion 228 d ₁ on a sideadjacent nub 228 d ₃. Lever 228 d ₆ includes a tip 228 d ₇ configuredsuch that biasing member 228 d ₅ is located distal or proximal of nub228 d ₃.

In use, as slider 228 d is moved distally and proximally relative tohousing 102 of electrosurgical pencil 100, nub 228 d ₃ moves along VDN127 thereby affecting VDN 127 while tip 228 d ₇ of lever 228 d ₆ of thespring lever assembly inter-engages with detents or tactile features 131formed in housing 102 of electrosurgical pencil 100 to thereby provide adegree of tactile feedback to the user of electrosurgical pencil 100.Biasing member 228 d ₅ functions to maintain nub 228 d ₃ in contact withVDN 127 and tip 228 d ₇ of lever 228 d ₆ of the torsion spring leverassembly in contact with detents or tactile features 131 formed inhousing 102 of electrosurgical pencil 100. One advantage to using atorsion spring lever assembly configuration as set forth in FIG. 6D isthat such a configuration provides greater spring deflections withsmaller spring constants, thus making the delivered force less sensitiveto dimensional variations in slider 228 d.

Turning now to FIGS. 7A-7C, a series of sliders or intensity controllers328 according to an embodiment of the present disclosure is shown.Sliders 328 are configured to increase a contact force exerted on VDN127 while maintaining a degree of facility for an end user to moveslider 328 relative to housing 102 of electrosurgical pencil 100.

As seen in FIGS. 7A-7C, a slider 328 a may include a body portion 328 a₁ and at least one arm 328 a ₂ extending from body portion 328 a ₁ andconfigured for slidable engagement in guide channels 130 a, 130 b (seeFIG. 1) of electrosurgical pencil 100. Slider 328 a includes a lever 328a ₃ pivotally connected to body portion 328 a ₁. Lever 328 a ₃ includesa first end 328 a ₄ configured to extend above body portion 328 a ₁ anda second end 328 a ₅ configured to extend below body portion 328 a ₁.First end 328 a ₄ of lever 328 a ₃ is configured to selectively engagedetents or tactile features 131 formed in housing 102 of electrosurgicalpencil 100 and second end 328 a ₅ of lever 328 a ₃ is configured toselectively engage VDN 127.

As seen in FIG. 7A, slider 328 a may include a biasing member in theform of a coil or constant force spring 329 a, or as seen in FIG. 713slider 328 a may include a biasing member in the form of a tensilespring 329 b, or as seen in FIG. 7C slider 328 a may include a biasingmember in the form of a compression spring 329 c. Biasing members 329a-329 c are each configured or arranged so as to maintain first end 328a ₄ of lever 328 a ₃ in contact with or in engagement with detents ortactile features 131 formed in housing 102 of electrosurgical pencil 100and to maintain second end 328 a ₅ of lever 328 a ₃ in engagement withVDN 127. Biasing members 329 a-329 c may be secured to and extendbetween a suitable location on lever 328 a ₃ and a suitable location onbody portion 328 a ₁.

In use, as slider 328 a is moved distally and proximally relative tohousing 102 of electrosurgical pencil 100, first end 328 a ₄ of lever328 a ₃ inter-engages with detents or tactile features 131 formed inhousing 102 of electrosurgical pencil 100 to thereby provide a degree oftactile feedback to the user of electrosurgical pencil 100 while secondend 328 a ₅ of lever 328 a ₃ moves along VDN 127 thereby affecting VDN127. In particular, as first end 328 a ₄ of lever 328 a ₃ moves from onedetent or tactile features 131 to an adjacent detent or tactile features131, first end 328 a ₄ of lever 328 a ₃ is moved towards body portion328 a ₁ and second end 328 a ₅ of lever 328 a ₃ moves off of or reducesa pressure on VDN 127 and also is moved towards body portion 328 a ₁. Asfirst end 328 a ₄ of lever 328 a ₃ is moved into the adjacent detent ortactile features 131 second end 328 a ₅ of lever 328 a ₃ substantiallystrikes down onto, imparts or otherwise increases a pressure on VDN 127.

Turning now to FIGS. 8A and 8B, a series of sliders or intensitycontrollers 428 and a tactile mask 429 according to an embodiment of thepresent disclosure are shown. Sliders 428 are configured to increase acontact force exerted on VDN 127 while maintaining a degree of facilityfor an end user to move slider 428 relative to housing 102 ofelectrosurgical pencil 100. Tactile mask 429 is configured to causeslider 428 to impact or strike against VDN 127.

As seen in FIG. 8A, a slider 428 a may include a body portion 428 a ₁and at least one arm 428 a ₂ extending from body portion 428 a ₁ andconfigured for slidable engagement in guide channels 130 a, 130 b (seeFIG. 1) of electrosurgical pencil 100. Slider 428 a includes a springplunger assembly having a stem 428 a ₄ extending from body portion 428 a₁ and defining a recess configured to retain a biasing member 428 a ₅and a tactile feedback transmitting feature in the form of an actuator428 a ₆ therein. The spring plunger assembly is configured such thatactuator 428 a ₆ extends from a bottom surface of body portion 428 a ₁,in the direction of VDN 127.

Tactile mask 429 includes an elongate body portion 429 a configured tooverlie VDN 127. Body portion 429 a defines a plurality of apertures orwindows 429 b formed therein along a length thereof. Tactile mask 429 ispositioned over VDN 127 at a location such that apertures 429 b mayalign or register with variable resistance elements 144 d provided onlower layer 140 b of VDN 127 (see FIG. 5).

In use, as slider 428 a is moved distally and proximally relative tohousing 102 of electrosurgical pencil 100, actuator 428 a ₆ of springplunger assembly moves over and between apertures 429 b formed intactile mask 429. In so doing, actuator 428 a ₆ of spring plungerassembly impacts or strikes against VDN 127. Additionally, theinter-engagement of actuator 428 a ₆ of spring plunger assembly withapertures 429 b formed in tactile mask 429 provides a degree of tactilefeedback to the user of electrosurgical pencil 100.

As seen in FIG. 8B, a slider 428 b may include a body portion 428 b ₁and at least one arm 428 b ₂ extending from body portion 428 b ₁ andconfigured for slidable engagement in guide channels 130 a, 130 b (seeFIG. 1) of electrosurgical pencil 100. Slider 428 b includes a tactilefeedback transmitting feature in the form of a nub 428 b ₃ extending orprojecting from a bottom surface thereof, such as, for example, from abottom surface of body portion 428 b ₁. Slider 428 b further includes aspring lever assembly having a stem 428 b ₄ extending from body portion428 b ₁, on a side opposite nub 428 b ₃, and defining a recessconfigured to retain a biasing member 428 b ₅ therein. The spring leverassembly further includes a lever 428 b ₆ pivotally connected to bodyportion 428 b ₁ and having a tip 428 b ₇ configured to extend over oroverlie biasing member 428 b ₅. The spring lever assembly is configuredsuch that stem 428 b ₄ is located distal or proximal of nub 428 b ₃ andsuch that lever 428 b ₆ extends away from nub 428 b ₃.

In use, as slider 428 b is moved distally and proximally relative tohousing 102 of electrosurgical pencil 100, nub 428 b ₃ of slider 428 bmoves over and between apertures 429 b formed in tactile mask 429. In sodoing, nub 428 b ₃ of slider 428 b contacts VDN 127. Additionally, theinter-engagement of nub 428 b ₃ of slider 428 b with apertures 429 bformed in tactile mask 429 provides a degree of tactile feedback to theuser of electrosurgical pencil 100. Moreover, tip 428 b ₇ of lever 428 b₆ rides against an inner surface of housing 102 of pencil 100 andbiasing member 428 b ₅ act on tip 428 b ₇ of lever 428 b ₆ to exert aforce on body portion 428 b ₁ and thereby press nub 428 b ₃ of slider428 b against tactile mask 429.

Tactile mask 429 may be constructed from a rigid, semi-rigid ornon-rigid material, from a resilient or non-resilient material, from aconductive or non-conductive material, from any combination thereof, orfrom any material suitable for the intended purpose of definingapertures and transmitting forces through said apertures.

Turning now to FIGS. 9A and 9B, a series of sliders or intensitycontrollers 528 according to an embodiment of the present disclosure isshown. Sliders 528 are configured to increase a contact force exerted onVDN 127 while maintaining a degree of facility for an end user to moveslider 528 relative to housing 102 of electrosurgical pencil 100.

As seen in FIG. 9A, a slider 528 a may include a body portion 528 a ₁and at least one arm 528 a ₂ extending from body portion 528 a ₁ andconfigured for slidable engagement in guide channels 130 a, 130 b (seeFIG. 1) of electrosurgical pencil 100. Slider 528 a includes a biasingmember, in the form of a torsion spring 528 a ₃ pivotally supported onbody portion 528 a ₁ at pivot point “P”. Torsion spring 528 a ₃ includesa first leg 528 a ₄ extending from pivot point “P” and configured toengage a surface of housing 102 of electrosurgical pencil 100, and asecond leg 528 a ₅ extending from pivot point “P” and configured toengage VDN 127. As seen in FIG. 9A, first leg 528 a ₄ of torsion spring528 a ₃ extends above body portion 528 a ₁ and second leg 528 a ₅ oftorsion spring 528 a ₃ extends below body portion 528 a ₁.

In use, as slider 528 a is moved distally and proximally relative tohousing 102 of electrosurgical pencil 100, second leg 528 a ₅ of torsionspring 528 a ₃ moves along VDN 127 thereby affecting VDN 127 while firstleg 528 a ₄ of torsion spring 528 a ₃ inter-engages with detents ortactile features 131 formed in housing 102 of electrosurgical pencil 100to thereby provide a degree of tactile feedback to the user ofelectrosurgical pencil 100. As first leg 528 a ₄ of torsion spring 528 a₃ is flexed downwardly, in the direction of body portion 528 a ₁, asslider 528 a is moved distally and proximally relative to housing 102 ofelectrosurgical pencil 100, second leg 528 a ₅ of torsion spring 528 a ₃is pressed more or less into the surface of VDN 127.

As seen in FIG. 9B, a slider 528 b may include a body portion 528 b ₁and at least one arm 528 b ₂ extending from body portion 528 b ₁ andconfigured for slidable engagement in guide channels 130 a, 130 b (seeFIG. 1) of electrosurgical pencil 100. Slider 528 b includes a linkassembly 528 b ₃ pivotally supported on body portion 528 b ₁ at pivotpoint “P”. Link assembly 528 b ₃ includes a first leg 528 b ₄ extendingfrom pivot point “P” and configured to engage a surface of housing 102of electrosurgical pencil 100, a second leg 528 b ₅ extending from pivotpoint “P” and configured to engage VDN 127, and a biasing member 528 b ₆interposed between first leg 528 b ₄ a second leg 528 b ₅. As seen inFIG. 9B, first leg 528 b ₄ of link assembly 528 b ₃ is in registrationwith or extends above second leg 528 b ₅ of link assembly 528 b ₃.

In use, as slider 528 b is moved distally and proximally relative tohousing 102 of electrosurgical pencil 100, second leg 528 b ₅ of linkassembly 528 b ₃ moves along VDN 127 thereby affecting VDN 127 whilefirst leg 528 b ₄ of link assembly 528 b ₃ inter-engages with detents ortactile features 131 formed in housing 102 of electrosurgical pencil 100to thereby provide a degree of tactile feedback to the user ofelectrosurgical pencil 100. As first leg 528 b ₄ of link assembly 528 b₃ is moved downwardly, in the direction of body portion 528 b ₁, asslider 528 b is moved distally and proximally relative to housing 102 ofelectrosurgical pencil 100, biasing member 528 b ₆ transmits forces tosecond leg 528 b ₅ of link assembly 528 b ₃ to press more or less intothe surface of VDN 127.

Although the subject apparatus has been described with respect topreferred embodiments, it will be readily apparent, to those havingordinary skill in the art to which it appertains, that changes andmodifications may be made thereto without departing from the spirit orscope of the subject apparatus.

1. An electrosurgical pencil, comprising: an elongated housingconfigured to support an electrocautery electrode extending distallytherefrom; at least one voltage divider network supported on thehousing, the at least one voltage divider network operable toelectrically connect to the source of electrosurgical energy forcontrolling at least one of an intensity and a mode of electrosurgicalenergy being delivered to the electrocautery electrode; and an intensitycontroller slidably supported on the housing, wherein the intensitycontroller is configured to exert a force on the at least one voltagedivider network and provide a tactile feedback to a user of theelectrosurgical pencil as the intensity controller is moved relative tothe housing.
 2. The electrosurgical pencil according to claim 1, whereinthe intensity controller includes a lever pivotally connected to a bodyportion thereof and contactable with the housing and the at least onevoltage divider network.
 3. The electrosurgical pencil according toclaim 2, wherein the lever includes a first end configured forengagement with a tactile feature formed in the housing.
 4. Theelectrosurgical pencil according to claim 3, wherein the lever includesa second end configured for engagement with the at least one voltagedivider network.
 5. The electrosurgical pencil according to claim 3,wherein the intensity controller includes a biasing member configured tomaintain a first end of the lever in contact with the tactile featureformed in the housing.
 6. The electrosurgical pencil according to claim4, wherein the intensity controller includes a biasing member configuredto maintain a second end of the lever in contact with the at least onevoltage divider network.
 7. The electrosurgical pencil according toclaim 2, wherein the intensity controller includes a biasing memberconfigured to maintain a first end of the lever in contact with thetactile feature formed in the housing and to maintain a second end ofthe lever in contact with the at least one voltage divider network. 8.The electrosurgical pencil according to claim 7, wherein the biasingmembers is one of a coil spring, a tension spring and a compressionspring.
 9. The electrosurgical pencil according to claim 7, wherein thetactile feature includes one or move adjacent detents.
 10. Theelectrosurgical pencil according to claim 9, wherein movement of thefirst end of the lever into the one or more adjacent detents causes thesecond end of the lever to substantially strike the at least one voltagedivider network.
 11. An electrosurgical device configured for connectionto a source of electrosurgical energy, the electrosurgical devicecomprising: a housing; an electrical circuit supported within thehousing, the electrical circuit being connectable to the source ofelectrosurgical energy; and a controller slidably supported on thehousing, wherein the controller is configured to exert a force on theelectrical circuit to affect a change in the electrical circuit and toexert a force on a surface of the housing to provide a tactile feedbackto a user of the electrosurgical device as the controller is movedrelative to the housing.
 12. The electrosurgical device according toclaim 11, wherein the electrical circuit comprises at least one voltagedivider network capable of controlling at least one of an intensity anda mode of electrosurgical energy being delivered, and wherein thecontroller includes a lever pivotally connected to a body portionthereof and contactable with the housing and the at least one voltagedivider network.
 13. The electrosurgical device according to claim 12,wherein the lever includes a first end configured for engagement with atactile feature formed in the housing.
 14. The electrosurgical deviceaccording to claim 13, wherein the lever includes a second endconfigured for engagement with the at least one voltage divider network.15. The electrosurgical device according to claim 13, wherein thecontroller includes a biasing member configured to maintain a first endof the lever in contact with the tactile feature formed in the housing.16. The electrosurgical device according to claim 14, wherein thecontroller includes a biasing member configured to maintain a second endof the lever in contact with the at least one voltage divider network.17. The electrosurgical device according to claim 12, wherein thecontroller includes a biasing member configured to maintain a first endof the lever in contact with the tactile feature formed in the housingand to maintain a second end of the lever in contact with the at leastone voltage divider network.
 18. The electrosurgical device according toclaim 17, wherein the biasing members is one of a coil spring, a tensionspring and a compression spring.
 19. The electrosurgical deviceaccording to claim 17, wherein the tactile feature includes one or moreadjacent detents.
 20. The electrosurgical device according to claim 19,wherein movement of the first end of the lever into the one or moreadjacent detents causes the second end of the lever to substantiallystrike the at least one voltage divider network.